2013 TAPPI Linerboard/Medium Manufacture Course
                           2013 LINERBOARD & MEDIUM  MANUFACTURE COURSE
                                 PRELIMINARY COURSE  SCHEDULE
Subject to Change
Supplemental  Overview of Linerboard Seminar                                                 
Monday, August 12 

8:00 – 5:00
Overview of Corrugating
Overview of  Tests & Properties
Overview of Pulp Mill Operations & Recycling                          
Overview of Stock Preparation
Overview of Paper Machine Operations
 Day 1  Tuesday,  August 13
      8:00 – 8:30       Welcome, Introductions,   Learning Objectives
      8:30 – 12:00     The Corrugating Process (overview of equipment/operations & focus on how to improve bonding between the liner and medium)
  •  Double-Wall Corrugator Wet End Summary  
                 Identify main components of a Corrugated Web:
                    Liner, Medium, Adhesive
  • Lay-out of Equipment (Numbering/Stations)                        
   Single-facer #1 Liner Splicer (position 3)
      Liner roll stand (position 3)
      Medium Splicer (position 2)
      Medium roll stand (position2)
      Medium pre-conditioner
      Bridge Elevator Belt.
Double-facer Liner Splicer (position 1)                       
Double-face Liner rollstand (position 1)
Triple pre-heater
      a. Function
      b. Wrap-arms
Glue Unit
       a.  Function
       b. Additional preheaters
  • Corrugator Terms and Variables 
         Corrugated Board
               Single Face
               Single Wall
               Double Wall
               Triple Wall
           Paper Grades
                Basis Weight
                Standard weights
           Construction of Box  
                 Box Blank
          Paper Characteristics  
               Liners (Two sides), Medium
               Basis Weight                          
  • Optimizing Bonding in the Corrugator                                                              
            a.    Application step
            Application is the first stage of the adhesive bonding process. The applications differ slightly for the single-face liner and the                double-face liner. The application stage relates to the amount of starch applied to the flute tips.  
            b.    Wetting and Penetration step                                                            
            Critical to the strength of the bond. Several variables can affect this phase. (more on this topic in Process Control section).                   Both medium and liner papers must have the starch penetrate their surface.  
            c.    Gelatinization  & Green Bond steps                                              
            This Green Bond holds paper together, but still contains a significant amount of moisture.
            d.    Evaporative Bond - Wetting/Penetration (DF) steps
            Controlling factors: temperature, pressure, speed
            Evaporative bond mechanisms during the first 2-3 seconds                
            e.   Gelling & Green Bond for Pressure Bond (DF) steps
            Mechanisms during bond formation
            f.    Drying/Fully Curing step
            Final Evaporative bond formation in the final 1-2 seconds.
12:00 – 1:00      LUNCH
1:00 – 5:00        Linerboard & Medium Performance Properties & Tests
     (focus is on liner and medium performance properties and tests; and how the liner & medium properties affect corrugator runnability)
     What happens to the Linerboard & Medium in the Corrugating Process
     Sheet Structure & why it’s important, MD/CD Fiber Orientation, Formation
     Properties & Tests, what they are telling us, and what contributes to their values
                          Stiffness, Ring Crush, Mullen, Concora
                          Edgewise Compression Test, STFI
                          Tensile, Modulus, Stretch
                          Liquid Absorption, Porosity, Adhesion
                          Sizing tests, Cobb, Water drop, etc.
                         Moisture & Humidity Effects on Performance Properties
                         Causes of  Curl, Warp, & Wash Boarding
                         Viscoelastic Creep Failure of Boxes
                         Printability & Smoothness
               CASE STUDIES - How Properties affect Runnability on the Corrugator
               Others, as per pre-course survey of participants
      5:30   Adjournment
Day  2
Wednesday, August 14, 2013

8:00 – 10:00
      Improving Performance I : Fiber Raw Materials,  Pulp Properties                                
•    Fiber Properties & Effects on Sheet Structure  
•    Pulping Processes for Liner & Medium
 10:00 – 11:00  
 Improving Performance  II: Recycling                                                
•    Recycled Fiber Quality
•    Stickies         
      11:00 – 12:00
Improving Performance III: Stock Prep Refining                                  
•    Refining mechanism
•    Effects on sheet and properties
•    Refining Measurements and Variables
•    Improving Refining for Linerboard & Medium
12:00 – 1:00  LUNCH
1:00 – 4:00
Improving Performance III: Chemical Additives                                 
          pH control
•    Dry & Wet Strength  
•    Sizing
•    Fillers
•    Formation Aids, Retention
•    Wet End Chemistry Improvement
4:00 – 5:00
Case Studies
•    Chemical Additives & Effects
•    Refining
5:00 Adjournment
Day 3
   Thursday, August 15, 2013   
       8:00  - 10:00
Improving Performance IV: Paper Machine Wet End Operations     
•    Approach system   
•    Headbox operations
           Importance of and Variables affecting Formation  
           Microturbulence Strategies
          Jet/Wire & MD/CD Orientation
          Structure CD, MD, Z Variations
          Headbox Crossflows & BW profile control
•    Sheet forming
            Formation Improvement & Microturbulence
            Top Sheet Forming
            Twin Wire Gap Formers, Hybrid Formers
10:00 – 11:00  
TSI/TSO Analysis & Case Studies                                              
11:00 – 12:00
Improving Performance V: Pressing, Drying, Calendering      
•    Pressing Mechanism of Water Removal; Effect on Sheet Properties Shoe Pressing & other developments
•    Effects of Drying and Shrinkage & Moisture profile on Liner & Medium sheet & properties
•    Types of calenders & variables affecting calendering
•    Calender box surface treatments
•    Winding  
 12:00 – 1:00  LUNCH
 1:00 – 2:30
Improving Performance VI : Machine Clothing                           
•    Forming Fabrics
•    Wet Press Fabrics
•    Drying Fabrics
2:30 -3:30
Paper Machine Operations VI : Size Press & Other Surface Treatments                                                                              
•    Variables affecting pick up
•    Developments in Size Press
•    Surface Treatment Chemicals & Coatings  to Improve Linerboard  
3:30- 4:30
Printability, Developments in Printing & Demands on Linerboard & Medium            
           Preprint and Post Print
           Linerboard surface requirements
           Flexo process improvements
             Photopolymer plates and packing materials
             High definition halftones
             Staccato screening
             More colors
           Digital printing of corrugated
             High speed pigmented ink jet
             Surface quality requirements
4:30  Wrap up, evaluations and adjournment